AbstractThe feasibility of plasma spray deposition of polyamide 11 on steel has been investigated. The conditions for he preparation of high integrity deposits have been established by the control of precursor powder injection,torch traverse speed, and arc power. The optimal deposition conditions are designed to produce complete particle melting in the plasma, extensive flow on impact, and minimal thermal degradation. The study of the deposited layers revealed a significant loss incrystallinity and the presence of a minor metastable phase as a result of rapid solidification. Under nonoptimal deposition, substantial thermal degradation occurred for which a chain scission mechanism is proposed. No oxidation of the polymer was detected even though spraying was carried out in air.